ASTRO ATS-8900 TABBER/STAMP AFFIXER OPERATOR MANUAL

Transcription

1 ASTRO ATS-8900 TABBER/STAMP AFFIXER OPERATOR MANUAL

2 SAFETY PRECAUTIONS THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. OBSERVE THE FOLLOWING SAFETY RULES WHEN OPERATING THE ASTRO ATS-8900 TABBER, LABELER, AND STAMP AFFIXER. BEFORE USING THE ATS-8900, READ THIS MANUAL CAREFULLY AND FOLLOW RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS: Keep hands, hair, and clothing clear of rollers and other moving parts. Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure machine mechanisms come to a stop. Always turn off the machine before making adjustments, cleaning the machine, or performing any maintenance covered in this manual. Use the power cord supplied with the machine and plug it into a properly grounded, easily accessible wall outlet located near the machine. Failure to properly ground the machine can result in severe personal injury and/or fire. Power cord and wall plug are the primary means of disconnecting the machine from the power supply. DO NOT use an adapter plug on the line cord or wall outlet. DO NOT remove the ground pin from the line cord. DO NOT route the power cord over sharp edges or trap it between furniture. Avoid using wall outlets controlled by wall switches, or shared with other equipment. Make sure there is no strain on the power cord caused by jamming between equipment, walls or furniture. DO NOT remove covers. Covers enclose hazardous parts that should be accessed by a qualified service representative. Report any cover damage to your service representative. This machine requires periodic maintenance. Contact your authorized service representative for required service schedules. To prevent overheating, do not cover the vent openings. Use this equipment only for its intended purpose. In addition, follow any specific occupational safety and health standards for your workplace or area. This manual is intended solely for the use and information of Astro Machine Corp. its designated agents, customers, and their employees. The information in this guide was obtained from several different sources that are deemed reliable by all industry standards. To the best of our knowledge, that information is accurate in all respects. However, neither Astro Machine Corp. nor any of its agents or employees shall be responsible for any inaccuracies contained herein. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher

3 TABLE OF CONTENTS TABLE OF CONTENTS SECTION 1 Getting Acquainted 1 Front View 1 Tabber Rear View 2 FF-30 Feeder Connections 3 Tabber Control Panel 4 SECTION 2 - Assembly and Installation 5 Assembly 5 Installing the Reel Assembly 5 Install FF-30 Feeder 6 SECTION 3- Operating the Tabber 8 Adjusting the Feeder 9 Adjusting the Tabber 10 Adjusting Tab Fold Positioning 11 Operating the Tabber 13 Exceeding Tabbing Rate 14 Running a Pre-Programmed Job 15 SECTION 4 Programming the Tabber 17 Advanced Soft Key 17 Control Panel Backlight 17 Version 18 Diagnostic 18 Job # Key 18 Automatic Tab Sensor (V-Tab) Adjustment 19 Manual Tab Sensor (V-Tab) Adjustment 21 Manual Tab/Stamp Positioning Features 23 Automatic Tab/Stamp Positioning Features 27 Manual Product Length Input 29 SECTION 5 Maintenance 30 Cleaning 30 Rollers and Transport Belts 30 Cleaning the Sensors 30 Lubrication 32 SECTION 6 Troubleshooting 33 Jams 33 Tab Placement Problems 33 Stamp Placement Problems 35 Tabber Operation Problems 36 Diagnostics 37 Appendix - Specifications 40 Index 41 i

4 NOTES ii

5 GETTING ACQUAINTED SECTION 1 Getting Acquainted Front View 1 Control Panel Control and program Tabber. 2 Pressure Roller Assembly Presses tab to media. 3 Reel Load tabs or stamps on Reel Assembly. 4 Take-up Reel Winds up tab web after tab is applied. 5 Media Height Adjustment Knob Permits operator to raise or lower Head Assembly to adjust for media thickness. 6 FF-30 Feeder Assembly Used to feed media to Tabber. 7 Feeder Interface Cable When connected to Tabber, allows Tabber to control Feeder. 8 Media Support Supports media while it is being fed. 9 Media Guides Help hold media in place while it is being fed. 1

6 GETTING ACQUAINTED Tabber Rear View Emergency Stop Input Permits an Emergency Stop of Tabber from an existing safety circuit when properly wired. Jumper plug must be used when this feature is not used. Emergency Stop Output Permits Tabber to control emergency stopping of another machine. Tabber/Feeder Control Cable Connect Feeder here to permit automatic operation of Feeder when used with Tabber. 4 Main Power Switch Turns Tabber ON and OFF. 5 Fuse Main power fuse for Tabber. 6 Power Inlet Connection Power Cord plugs in here. 2

7 GETTING ACQUAINTED FF-30 Feeder Connections 1 Tabber/Feeder Control Cable Permits Tabber to control Feeder when Mode Switch is in the Automatic position. 2 Power Inlet Connection Power Cord plugs in here. 3 Fuse Feeder Fuse is located here. 4 Main Power Switch Turns Feeder ON and OFF Mode Switch Selects either Automatic mode (Tabber controls Feeder) or Manual mode (Feeder speed is controlled manually by Feeder Speed Control). Feeder Speed Control Controls Feeder speed when Feeder Mode Switch is in Manual position. Media Thickness Adjustment Adjusts height/pressure of Forwarding Rollers (Exit Rollers) to accommodate media thickness. 3

8 GETTING ACQUAINTED Tabber Control Panel 1 TRANSPORT POWER SWITCH Turns Tabber transport power ON*. 2 SPEED CONTROL Adjusts Tabber speed. NOTE: Maximum speed of Tabber is controlled by software. Tabber Speeds: Single Tabs: Applies up to 20,000 pieces per hour Double Tabs: Applies 12,000 pieces per hour Triple Tabs: Applies 8,000 pieces per hour. (Exceeding these speeds causes Tabber to stop.) 3 LCD DISPLAY Keeps operator informed of Tabber status. 4 KEY PAD Used to set the adjustments and program the Tabber 5 EMERGENCY STOP When Tabber is properly connected to Feeder and/or other pieces of equipment, pushing this button stops all machines. Turn button clockwise to release (reset) it. 6 SOFT KEYS Used to step through various menu options to program Tabber. 7 STOP KEY Stops Tabber and holds it in a ready state to resume operation. 8 RUN KEY Press to start Tabber when running a job. 9 INFO KEY Press to change display to Information mode. 10 SAVE KEY Used to save entries into memory. 11 CLEAR KEY Press to clear any incorrect entry before it is saved in memory. *Transport power will not activate unless all safety and emergency stop circuits are closed. 4

9 ASSEMBLY AND INSTALLATION SECTION 2 - Assembly and Installation The ATS-8900 is shipped in a single carton. Assembly Choose a Location Place the Tabber with its Feeder on a sturdy worktable or cabinet at least 12 inches from any walls. Allow enough room to place the Feeder on the same work surface. Protect the Tabber from excessive heat, dust, and moisture avoid placing it in direct sunlight. CAUTION THE UNIT IS HEAVY. IT IS STRONGLY RECOMMENDED THAT TWO TECHNICIANS REMOVE THE TABBER FROM THE CARTON AND PLACE IT ON THE WORKING SURFACE. Installing the Reel Assembly 1. Place the Reel Assembly over the Guide Pin [1]. Make sure that the Head is over Guide Pin [2] while you are tightening the Tab Positioning Knob [3] clockwise. NOTE: Make sure the plastic bushings [4], located at the front and back of the hole for Guide Pin [1], are installed. 5

10 ASSEMBLY AND INSTALLATION 2. When the Reel Assembly is completely seated, plug in the Reel Assembly Cord [5], as shown. Install FF-30 Feeder 1. The pin [A] on the Feeder should mate with the hole [B] on the Tabber body. 2. The Feeder is properly aligned with the Tabber body as shown. 6

11 ASSEMBLY AND INSTALLATION Plugging in the Feeder and Tabber Make sure that the Emergency Stop Switch of the Tabber is in the OFF position and the Main Power Switch above the power cord receptacle is in the OFF position. Make sure that the Power Switch on the Feeder is in the OFF position also. 1. Connect one end of the Tabber power cord [1] to the rear of the Tabber in the corresponding receptacle. 2. Connect one end of the Feeder power cord [2] to the rear of the Feeder in the corresponding receptacle. 3. Plug the other end each cord into a Volt AC, 50/60 Hz. grounded outlet. CAUTION Do not use adapter plugs or extension cords to connect the Tabber or the feeder to the wall receptacle. Do not use outlets controlled by wall switches. Do not use an outlet that shares the same circuit with large electrical machines or appliances. 4. Connect Feeder Interface Cable [3] to Feeder and to lower connector on Tabber. 7

12 OPERATING THE TABBER SECTION 3- Operating the Tabber ATS-8900 is capable of applying up to three tabs or stamps to the media in one pass. The steps required to set-up the Tabber for applying tabs or stamps are: Load tabs or stamps Set up the feed Set up the Tabber Program the Job Run the Job WARNING! BEFORE LOADING TABS OR STAMPS TURN OFF THE TABBER OR PRESS THE EMERGENCY STOP BUTTON TO PREVENT THE TAB DRIVER ROLLER FROM TURNING DURING THE LOADING PROCESS Loading Tabs/Stamps 1. Remove the Reel Side Guide and install the Tab Roll with the tabs unwinding face up from the right side of the roll. Remove approximately 30 tabs from the roll to create a leader. 2. Release the Unwind Drive Press Roller by rotating it to the left and thread the leader over the Unwind Drive Roller. Rotate the Unwind Drive Press Roller so that it contacts the Unwind Drive Roller. 3. Thread the leader into the Bin then over the Bin Idler Roller. Adjust the Roller Tension Spring so that it lightly touches the tab backing. 4. Continue threading the leader under the Idler Roller then through the slot in the Tab Sensor and Applicator. Tip: It is easier to thread the tabs through the Tab Applicator when the Media Thickness Control Knob is turned fully clockwise (transport pressure raised to its highest position). 5. Lift the Drive Press Roller, and then thread the leader between the Drive Roller and the Drive Press Roller. Bring the Drive Press Roller in contact with the Drive Roller 6. Thread the web over the Take-up Idler Roller and the loop the web over the pegs in the Take-up Reel. 7. Make sure that the Adjustable Web Guides on the Idler Rollers and Take-up Idler Roller lightly contact the edge of the Tab backing. 8

13 OPERATING THE TABBER Adjusting the Feeder The Feeder is properly aligned with the Tabber when it is installed. The Operator Side Guide in the Feeder is fixed in position for proper alignment of the media. Adjusting the Feeder to feed media: 1. Open the non-operator Side Guide to provide room for the media. 2. Loosen the Separator Locking Knobs and raise the Sheet Separators. Install one sheet of media under the Separators and lower Separators to contact the media. Tighten the Locking Knobs. NOTE: For media thicker than 1/2-folded sheets add one sheet of the material to the media before tightening the Locking Knobs. This gives thicker media a little more room to feed. 9

14 OPERATING THE TABBER 3. Move the Adjustable Side Guide to within 1/32-inch of the media and tighten the Locking Knob. 4. Adjust the Rear Media Support Guide so that the media is approximately 1/2-inch above the Media Support as shown. NOTE: This is a starting guideline. Height of media above Support Guide may vary to obtain optimum feeding. 5. Forwarding Rollers on the Feeder are adjustable for media thickness. This is particularly helpful when feeding media over 1/8-inch thick. To adjust the Forwarding Rollers, loosen the Locking Knob [3], place a piece of media under the Forwarding Rollers [4], and then tighten the Knob. NOTE: To increase or decrease the pressure on the Forwarding Rollers, adjust the lever [5] while tightening the Locking Knob [3]. Adjusting the Tabber The Tabber is equipped with two Paper Guides and an adjustable set of Angular Rollers to help guide the media into position for tabbing. Adjust these Guides as follows: 1. Place one of the two Media Guides next to the Fixed Media Guide. Then place the Adjustable Guide next to it as shown in the photo. 10

15 OPERATING THE TABBER 2. The two Media Guides [1] should be just resting on the belts. Too much pressure will cause the media to stall while being fed. Additionally, the Guides should be positioned between 1/8" and 1/4" of the edge of the media to prevent the edges from curling. The Center Media Guide [2] should be placed so that the Guide Rollers are on the belt nearest to the Fixed Media Guide [3]. The Center Media Guide [2] should not be placed on any other belt except the one nearest to one of the Fixed Media Guides [3]. NOTE: The Center Media Guide [2] can be set at an angle to increase the push against the Fixed Media Guide [3]. Additionally, all of the Guide Rollers on the Center Media Guide [2] should be riding on the same Transport Belt. Adjusting Tab Fold Positioning Once the tabs are loaded, the next step is to adjust the tab positioning. 1. Loosen Locking Knob [1] that holds Exit Roller Assembly in position, then slide it in the direction of the arrow. Lift the Exit Roller Assembly and pivot it to the right. 2. Applicator Head can be positioned two ways: Position A is used for applying tabs. Position B is used for applying stamps. Press down on the Locking Lever [2] and slide the Applicator Head into the appropriate position. 11

16 OPERATING THE TABBER 3. Release the two Press Rollers to take the tension off the Tab web. 4. Pull the Tab from the take-up end of the web until approximately 1/2 of the Tab/Stamp is showing. 5. Adjust the Tab Position Knob [5] to center the Tab on the edge of the belt as a starting point. 6. Adjust the tab web so that it is in position against the back of the Reel Guide and the Spring Guides on the Idler Rollers are lightly touching the tab web. 7. Insert one piece of media [3] into the front of the Tabber and adjust the Media Thickness Control Knob [4] up or down until you feel a drag on the piece of media. 12

17 OPERATING THE TABBER 8. Release the Emergency Stop Switch. Turn the Main Power Switch on the Tabber and the Feeder ON. If the Feeder Interface Cable is attached, make sure that the Selector Switch on the Feeder is set to Automatic. 9. Refer to the instructions under Operating the Tabber and run one piece through the Tabber. 10. Check the positioning of the Tab or Tabs on the piece and adjust the Fine Positioning Knob [5] to center the Tab on the piece. Turning the Knob clockwise will place more of the Tab on the bottom of the piece and turning the Knob counterclockwise will place more of the Tab on the top of the piece. 11. When you are satisfied with the tab-positioning, run the job. Operating the Tabber Start up the Tabber in the following sequence: 1. Check that the Emergency Stop Switch is in the operate position. Turn the Tabber ON by pressing the Main Power Switch on the Feeder and the Main Power Switch on the Tabber, then press the Green Transport Power Switch on the Tabber Control Panel. NOTE: If Feeder Interface Cable is installed, make sure that Feeder Selector Switch is set to Automatic so the Speed Control on the Tabber will control Feeder speed. 2. Start-Up screen at right appears. Soft keys (at bottom of display) control the following functions: a. Job # - Used to select one of four programmable jobs. More information can be found under Programming the Job section. b. Pass-Thru When Pass-Thru is showing, the Tabber will tab pieces as they are fed through it. Pressing this soft key will take the Tabber out of the tabbing mode and puts it in the pass-through mode. In Pass-Thru mode, display shows Operate. When Operate is showing, motor and main drive belts of the Tabber will run, but Tabber will not tab. This mode is used when the Tabber is in-line with other equipment and you do not want to tab the pieces going through the machine. 13

18 OPERATING THE TABBER c. Advanced Press this key to place the Tabber in Advanced Mode. This mode is used to select the Automatic Tab Sensing Program and to access more information regarding the soft key menus. 3. Press RUN key (located below soft keys on Control Panel) to start the Tabber. Adjust the Speed Control to set the speed of the Tabber. Press the STOP key located below the soft keys to stop the Tabber. Pressing the large Emergency Stop button will shut down the entire Tabber and lock out the other keys. To restart from an Emergency Stop, release the button by turning it clockwise, then press the RUN key. When the Tabber is running, the screen at right appears. It contains the following information: a. The number of the programmed job that is running. b. The number of tabs being applied to the piece. c. The rate or speed in pieces per hour. d. The number of pieces that have been run. This can be reset by pressing the CLEAR key on the Control Panel before starting the job. Operation of the Tabber is the same whether you are tabbing, applying labels or stamps. Refer to the parts of this section regarding setting up the Tabber for the type of application you are performing for more information. Exceeding Tabbing Rate IMPORTANT THE MAXIMUM SPEED OF THE TABBER IS CONTROLLED BY THE SOFTWARE. TABBER SPEEDS: SINGLE TABS APPLIES UP TO 20,000 PIECES PER HOUR, DOUBLE TABS APPLIES 12,000 PIECES PER HOUR, TRIPLE TABS APPLIES 8,000 PIECES PER HOUR. EXCEEDING THESE SPEEDS WILL CAUSE THE TABBER TO STOP. THE TAB PLACED ON THE END OF THE PIECE IS NOT COUNTED IN THE ABOVE. If you exceed the maximum speed of the Tabber for the job you are running the Run Screen changes and the Exceeding Tabbing Rate message flashes for 15 seconds. 14

19 OPERATING THE TABBER After 15 seconds*, if the Tabber isn't slowed down, Maximum Tabbing Rate Exceeded screen appears and the Tabber will stop. To restart, reduce Tabber speed and press RUN key on Control Panel. *If the Tabber is slowed down during the warning period it will switch back to the Run Screen and continue to operate. Running a Pre-Programmed Job Up to four jobs may be programmed into the Tabber's memory. To run a pre-programmed job release the Emergency Stop Button, then: 1. Press the Job # soft key. 2. Select the Job (1-4) you wish to run. In our example, we are selecting Job # 2 using the soft key Select Option to Edit screen appears. Press RUN key on Control Panel to start Tabber. NOTE: To check the setup, press and hold the INFO key on the Tabber Control Panel and a screen appears containing the settings and adjustments for the job you are running. 15

20 OPERATING THE TABBER INFO SCREEN INFORMATION Item Job # #Tabs Tab Pitch Paper-L Offset TabV Trip Tab Type Description The number of the Job that is currently selected. The number of Tabs being applied. The distance between the lead edge of the tab and the next tab including the space between tabs, plus 0.01". The length of the piece in inches. Distance from the leading edge of mail piece to leading edge of tab/stamp. The voltage on the Sensors when a tab is present under the Sensors. Clear and Opaque Tabs will have different voltage readings. This voltage is used to determine the difference between the Tab and the Backing to cause the tab to feed. There are two tab types: Clear and Opaque. (See Appendix B for samples.) 4. Pressing the RUN key changes the screen to the running mode so that the Rate in Pieces per Hour and the number of Pieces Run are displayed. 5. To stop the Tabber, press the Red Stop key next to the RUN key on the Control Panel. 16

21 OPERATING THE TABBER SECTION 4 Programming the Tabber Notes before Programming There are two methods of programming jobs on the Tabber: 1. Manual Where the operator specifies the tab positioning. 2. Automatic Where the Tabber is given the tab information and it automatically sets up the location of the tab or tabs by automatically measuring the piece. In either case some operator interaction to fine tune the tab location and media feed through the Tabber may be required. Here is an explanation of some of the functions and screens you will see when programming a job. Advanced Soft Key From Start-up screen, pressing the Advanced soft key displays several new soft keys. They are as follows: Control Panel Backlight Intensity of the Control Panel Backlight can be controlled from the Advanced soft key. To access the Backlight Control screen, press Advanced key, then Backlight key. Use the two arrow keys to adjust the intensity of the backlight. Click the BACK key to return the ATS-8900 to the operating mode. 50% is the normal setting. 17

22 OPERATING THE TABBER Version The Version soft key displays the following: Lifetime Products: Lifetime Tabs: BIOS Version: BACK: The total number of pieces transported through the system. Total number of Tabs/Stamps applied by the tab head. Software version currently loaded into the Tabber. Returns you to the Advanced features screen. Diagnostic The diagnostic function is for use by the Technical Representative to diagnose possible problems with the Tabber. Each screen performs a specific check of a function of the Tabber. It should only be used by a trained technician. See Diagnostics at the end of the Troubleshooting Section. Job # Key When Job # soft key is pressed (from Start-up screen), jobs that are already programmed and saved can be selected. Up to four jobs can be programmed into the Tabber's memory. Any of the jobs can be overwritten by simply reprogramming the Job # you select with new parameters. Once desired Job # is selected, the Select Setup Options screen appears. Manual Selects the Manual Tab/Stamp Positioning feature. Automatic Used to select the Automatic Tab Positioning feature. V-Tab Used to set the Tab Sensor Voltages for your tab/stamp stock. BACK Returns to previous screen. 18

23 OPERATING THE TABBER Automatic Tab Sensor (V-Tab) Adjustment Every time a new Tab/Stamp stock is used or a new job is set up, you must also set up the Tab Sensors for the Tab/Stamp stock. NOTE: To avoid wasting stamps, it is strongly suggested to manually program the V-Tab voltages, instead of using the Automatic feature. Automatic V-Tab Adjustment: 1. Turn Feeder OFF. 2. To begin programming, select Job # from the Press Run to tab using Job # screen. 3. Select the Job Number (1-4) you wish to use. In this example, we are selecting Job Number From the Select Setup Option screen, select V-Tab. 5. Select Automatic from the Tab Sensor setup screen. 6. The Select Tab Type before calibration screen appears. Select the type of tab, either Opaque or Clear, based on the table below. In this example we will select Opaque. 19

24 OPERATING THE TABBER Tip: The selection for Backing (liner) does not denote the type of tab material. Instead, it denotes the density of the tab and liner it is affixed to, as compared to the space between tabs. Rather than thinking of this setting as a backing description, it is easier to identity if the backing (liner) has a black bar between each tab or not (is space between tabs black or white?) See chart below. Backing Setting Color of Space Between Tabs Detailed Description Opaque White space between tabs Clear or translucent tab material with black dot, in the liner below each tab. Paper tab stock (white or colored). Stamps Clear Black space between tabs Clear or translucent tab material with black space (line), in the liner between each tab. Once the Tab Type is selected, the Tabber Transport will start and the screen at right appears. Adjust the Speed Control on Tabber up or down until Feed 1 Product now appears in the display. Feed one piece from the Feeder into the Tabber. Two or three tabs will be applied to the piece and then the Tabber will stop and display the new V-Tab values. Tab Sensor is now set up for this tab stock. IMPORTANT IN ORDER FOR THE TABBER TO DISTINGUISH BETWEEN THE TAB AND BACKING, THE VOLTAGE DIFFERENCE BETWEEN THE GAP V AND TAB V SHOULD BE HALF OF THE DIFFERENCE BETWEEN THE TWO VOLTAGES. IF THE TRIP VOLTAGE IS LESS THAN 0.50 VOLTS, CLEAN THE SENSOR. 1. Test the Tabber for proper operation. If you experience tab advancement or positioning problems, verify proper threading, transport setup, media length, tab type, and tab pitch settings. IMPORTANT IF TAB TYPE OR TAB PITCH VALUES NEED TO BE CHANGED, THEN THE AUTOMATIC TAB SENSOR ADJUSTMENT MAY ALSO NEED REPEATING. 20

25 OPERATING THE TABBER Manual Tab Sensor (V-Tab) Adjustment 1. Open the Exit Roller Assembly. 2. Begin programming by selecting Job# using soft key under display. 3. Select the Job Number (1-4) you wish to use for the job. In this example, we are selecting Job Number From the Select Setup Option screen, Select V-Tab. 5. Manually programming the V-Tab voltage. Begin by finding the Gap V or voltage return from the space between the stamps in this case. Release the Hold Down Roller Latch so that the stamps can slide easily through the Sensor. Move the stamp web through the Sensor until you obtain the lowest voltage reading, then press the Gap V key (1). Continue moving the stamp web through the Sensor until you obtain the highest reading, then press the Tab V key (2). When you are finished press the BACK key (3). IMPORTANT WHEN SETTING GAP VOLTAGE AND TAB VOLTAGE MANUALLY, THE SOFTWARE WILL DETERMINE IF THE TAB TYPE IS OPAQUE OR CLEAR BASED ON THE VOLTAGE READINGS YOU SELECT. 21

26 OPERATING THE TABBER Tab Type Description Gap V Level Tab V Level Opaque Tabs in which the space between the tabs is lighter than the tab even if the tab is white. Low High Clear Tabs with a black line between tabs. High Low 1. When finished, press the BACK key twice. 2. Close and lock the Exit Roller Assembly. 3. Lower the Pressure Roller Release Latch. 4. Test the Tabber for proper operation. If you experience tab advancement or positioning problems, verify proper threading, transport setup, media length, tab type and tab pitch settings. 22

27 OPERATING THE TABBER Manual Tab/Stamp Positioning Features Pressing the Manual soft key from the Select Setup Option screen puts the Tabber into the manual positioning mode. In this mode the operator must manually set the offset value (position) for each of the tabs/stamps being applied. Select Option to edit screen appears. # Tabs/Stmp. Select to set the number of tabs or stamps you would like to apply to the media. Position Select to set the position (offset values) for each tab/stamp to be applied to the media. Pitch Select to set Tab Pitch (distance from the top of one tab/stamp, to the top of the next tab/stamp) for the tab/stamp stock used. BACK Returns you to the previous screen. If you select 1 for # Tabs, the Select Option to edit screen reappears. If the # Tabs soft key is pressed: The display prompts you to select the number of tabs/stamps to apply to the mail piece. 1 Selects one tab/stamp 2 Selects two tabs/stamps 3 Selects three tabs/stamps BACK Returns you to the previous screen. What displays next depends on how many tabs have been selected: If you select 1 for # Tabs, the Select Option to edit screen will reappear. If you select 2 or 3 the Choose Placement Type screen appears: 23

28 OPERATING THE TABBER Separate Allows individual adjustment of each tab/stamp position via the Offset Value. Together Tabs/Stamps are placed next to each other, starting at the Offset Value (see below) set for Tab 1. BACK Returns you to the previous screen. Pressing the Position soft key prompts you to set the Offset Value for each Tab/Stamp, starting with Tab 1. Offset Value = Distance from leading edge of mail piece to leading edge of Tab/Stamp. Tab 1 Use this soft key to set the Offset Value for Tab/Stamp 1. Tab 2 Use this soft key to set the Offset Value for Tab/Stamp 2. Tab 3 Use this soft key to set the Offset Value for Tab/Stamp 3. BACK Returns you to the previous screen. If any of the Tab n (Tab 1, Tab 2, Tab 3) soft keys are selected, you will be asked to enter the Offset Value for the Tab Number you selected. NOTE: The number of Tab n choices you are presented with is based on the # Tabs and the tab placement (Separate, Together), that you previously selected. If # Tabs was set to 1 or tab placement Together was selected; you will be prompted to Enter Offset for Tab 1, as soon you press the Position key. Enter the desired Offset Value for Tab, using the numeric keypad. Then press the SAVE key. Press BACK. Repeat this process for each tab position. IMPORTANT THE TAB/STAMP POSITION IS BASED ON THE PLACEMENT OF THE BEGINNING OF THE TAB/STAMP WITH RESPECT TO THE LEAD EDGE OF THE PIECE. WHEN PLACING TABS/STAMPS, THE LENGTH OF THE TAB IS NOT CALCULATED. 24

29 OPERATING THE TABBER Tab Type Description Gap V Level Tab V Level Opaque Tabs in which the space between the tabs is lighter than the tab even if the tab is white. Low High Clear Tabs with a black line between tabs. High Low 1. When finished, press the BACK key twice. 2. Close and lock the Exit Roller Assembly. 3. Lower the Pressure Roller Release Latch. 4. Test the Tabber for proper operation. If you experience tab advancement or positioning problems, verify proper threading, transport setup, media length, tab type and tab pitch settings. 25

30 OPERATING THE TABBER Pitch Pitch is very important. The Pitch setting is how the software determines how far to advance the tab. When the Pitch soft key is pressed, the display prompts you to Enter Tab Pitch and press SAVE key. Pitch = Distance measured from the top of one tab to the top of the next tab. Select Pitch from the Select option to edit screen. Measure the distance from the top of one tab to the top of the next tab, in this example it was 1.190". Then add 0.01" for a total of 1.200". Enter that number using the number keys on the Control Panel and then press the SAVE key. BACK Returns to previous screen. 26

31 OPERATING THE TABBER Automatic Tab/Stamp Positioning Features Pressing the Automatic soft key from the Select Setup Option screen puts the Tabber into automatic positioning mode. The Tabber will automatically set Offset Values (positions) based on the product length and number of tabs selected.. 1 Tab Tab is applied centered along length of media. 2 Tabs Tabs are applied within 1" from each edge. 3 Tabs Two tabs are applied within 1" from each edge and one tab is centered. When Automatic is selected, the following choices appear: # Tabs Allows you to choose the Number of Tabs to apply to the media. Product-L Set the Paper Length of the media you are using. Pitch Set Tab Pitch (distance from the top of one tab/stamp, to the top of the next tab/stamp) for the Tab/Stamp stock used. BACK Returns you to the previous screen. If the # Tabs soft key is pressed the display prompts you to select the number of Tabs/Stamps to be applied to the mail piece. 1 Selects one tab/stamp 2 Selects two tabs/stamps 3 Selects three tabs/stamps BACK Returns you to the previous screen. 27

32 OPERATING THE TABBER Pressing the Product-L soft key from the Select Setup Option screen opens the Enter Product Length and press Save key screen. The following choices are displayed: Automatic Allows Tabber to automatically measure and set the piece length. It is highly recommended that you use Automatic to verify proper media feeding and sensing. IMPORTANT: Before pressing the Automatic soft key, make sure the Feeder is turned OFF and the Tabber's transport power switch is turned ON BACK Returns to previous screen. When the Automatic soft key is pressed, the display may prompt you to Increase Transport Speed or Decrease Transport Speed. Adjust the transport speed until the display shows Feed 1 Product now. When the display reads Feed 1 Product now, feed one of your mail pieces through the Tabber. NOTE: Feeding more than one mail piece will cause an incorrect length to be measured and set. After the piece has fed through the Tabber, the Tabber will stop and display the piece length. Verify the measurement! It must be accurate (+ or "). If the Tabber measures the piece to be longer than the actual piece length; then the media may be slipping or hesitating as it feeds. Check/Adjust the transport system. If the Tabber measures the piece to be shorter than the actual piece length; then the media may not be feeding straight (missing the Sensor), or a hole in the media may be traveling through the Sensor, or the Sensor may be getting reflection off the mail piece. If using a high gloss media, the sensor intensity may need to be adjusted lower by a qualified service person. If the media passes through without the Tabber providing a measurement the Media Sensor may be dirty. Try cleaning the Sensor as described in this manual. These problems need to be corrected before the Tabber will function correctly. 28

33 OPERATING THE TABBER Manual Product Length Input As an option, you can set the piece length manually. However, doing so will not fix a tab placement problem that is caused by a media feeding or media sensing issue. In other words, if the Tabber's Automatic Product Length feature is not reading the piece length accurately then setting the product length manually is NOT going to fix a problem. See Verify the measurement above. To manually enter the length of the media: 1. Measure the physical piece length, using the scale provided on the Control Panel. 2. Enter this Value, in inches and tenths of an inch, using the numeric key pad. 3. Press the SAVE key to accept and save this value. 4. Press the BACK soft key to return to the previous screen. Set Pitch Pitch is very important. The Pitch setting is how the software determines how far to advance the tab. When the Pitch soft key is pressed, the display prompts you to Enter Tab Pitch and press SAVE key. Pitch = Distance measured from the top of one tab to the top of the next tab. Select Pitch from the Select option to edit screen. Measure the distance from the top of one tab to the top of the next tab, in this example, 1.190". Then add 0.01" for a total of 1.200". Enter that number using the number keys on the Control Panel. Then press the SAVE key. BACK Returns you to the previous screen. 29

34 MAINTENANCE SECTION 5 Maintenance Cleaning WARNING! THE TABBER AND FEEDER ARE PRECISION MACHINES THAT SHOULD BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING ANY MAINTENANCE, DISCONNECT THEM FROM THEIR POWER SOURCE! The Tabber and Feeder must be cleaned regularly to remove accumulated paper dust and ink. Depending on the types of media run, paper dust may accumulate within machines and on the transport. To clean, unplug both machines from the power receptacle and remove the covers. Internal areas: Clean with a vacuum with a soft brush attachment to help loosen the dust particles. Take care not to damage the PC Boards or electrical wiring. Exterior: Clean with any standard non-abrasive household cleaner which does not contain plastic-harming solvents. CAUTION NEVER SPRAY OR POUR CLEANERS DIRECTLY ON OR INTO THE TABBER OR FEEDER. EXCESS LIQUID COULD HARM ELECTRONIC PARTS. ALWAYS DAMPEN A RAG WITH THE CLEANER AND APPLY IT TO THE PARTS TO BE CLEANED. Rollers and Transport Belts Belts and Rollers can become glazed with paper lint and ink from the media. Clean regularly with a mild abrasive household cleaner on a damp cloth. Avoid using solvents on Rubber Rollers. Cleaning the Sensors There are three Sensors in the Tabber; the Media Sensor located above the table of the Tabber, the Tab Sensor on the applicator head and Tab Web Sensor in the transport area. These sensors should be clean and free of accumulated paper dust. Use a vacuum with a soft brush attachment or dry compressed air to remove the dust. WARNING! DO NOT USE ABRASIVES OR LIQUIDS OF ANY KIND ON THE SENSOR LENS 30

35 MAINTENANCE Sensor Locations: MEDIA SENSOR TAB SENSOR TAB WEB SENSOR NOTE: To access the Tab Sensor, remove the Rear Cover; loosen the screw on the Tab Sensor Mounting Shaft. Remove the screw shown and slide the Sensor Assembly off the Mounting Shaft. Disassemble the Sensor Assembly and clean with a Q-tip. Media Sensor Test: There are two LED s located on the exit side of the Media Sensor. Green LED ON = Power Present Orange LED ON = No Paper (not interrupted) Orange LED OFF = Paper Present (interrupted) If the orange LED is not on when there is no paper present, then the reflector may need cleaning. If the orange LED comes ON even when paper is present, then the sensor intensity may need to be lowered. This is rare, but possible when high gloss media is being used. A qualified Astro service technician should make this adjustment. Tab Web Sensor Test: There are two LED s located on the exit side of the Tab Web Sensor. CAUTION To avoid tabs being driven from the Tab Reel and or personal injury from moving Rollers, please be sure to press the Emergency STOP button before testing the Tab Web Sensor. Green LED ON = Tabs/Stamp Present (interrupted) Orange LED ON = No Tabs/Stamps Present Clearing Tabs/Stamps To clear tabs/stamps and adhesive from inside the Tab Applicator Head and Tab Sensor, the Tab Applicator Head can be removed from the shaft and disassembled. This procedure should only be performed by a qualified Astro Service Technician. 31

36 MAINTENANCE Lubrication Several locations on the ATS-8900 Tabber require regular lubrication: 1. Place a small amount of white lithium grease where the Drive Press Roller Assembly touches the Release Cam. 2. Place a small amount of white lithium grease where Unwind Drive Press Roller Assembly touches the flat part of the Release Cam. 3. Lubricate Stepper Cam surface for the Head Raise Mechanism with white lithium grease (as shown). 32

37 TROUBLESHOOTING SECTION 6 Troubleshooting Troubleshooting Guide is provided to assist in solving any problems that might occur with the Tabber. We have tried to make it as complete as possible. The best advice we can offer is to make sure that the tabs, labels or stamps are threaded properly and that the machine is plugged in and turned on. Jams CONDITION Media jams in transport section of Tabber. Tab Placement Problems CONDITION SOLUTION 1. Check Feeder/Tabber alignment. Media should be between 1/8" to 1/32" from Fixed Guide in Tabber. 2. Check that the two Media Guides are not pressing down too firmly on the media. 3. Check that the Adjustable Center Guide is not pushing media tightly against the Fixed Side Guide. 4. Check that head pressure is not too tight. SOLUTION Tabs are not placed in same spot on media. Tabs should be placed within +/- 1/8" 1. Check Pitch setting for the tab. It should be " 0.010" more than the tab size plus the space between the tabs. 2. Check amount of transport pressure. Too little can cause media to slip when fed. 3. Check that pointer on the Applicator Head is in the center of the Tab. 4. Check that the pressure rollers (Unwind Roller and Tab Drive Roller) are engaged. 5. Verify that the correct Backing type was selected (Clear/Opaque). 6. Check/adjust V-Tab settings. More of the Tab is on the top of the media than on the bottom. Adjust the Tab Adjustment Knob (Page 12) clockwise to move more of the Tab to the bottom side of the media. 33

38 TROUBLESHOOTING CONDITION Less of the Tab is on the top of the media than on the bottom. SOLUTION Adjust Tab Positioning Knob (Page 12) counterclockwise to place more of the Tab to the top side of the media. Tab is not flush with the edge of the media. Media is not being fed flush with the Fixed Side Guide. There should be no more than 1/8" to 1/32" space between the media and the Fixed Side Guide when the media enters the Tabber. Check/Adjust Registration Assembly. When double tabbing one tab is not placed properly on the edge of the media. 1. Media may not be traveling along the Fixed Side Guide. Adjust angle of Guide Rollers by turning knob on Skew Guide. 2. Check pressure between the Head and the Transport. Too much pressure causes the media to flex as it is transported. Too little pressure causes media to skew as Tab is being applied. Two or three tabs applied next to each other. Programming issue. When programming for multiple tabs Together was selected instead of Separate. Or use the Auto Pos. feature. Reprogram the job. More than three tabs applied on each piece. 1. Wrong number of tabs selected. 2. Tab Sensor Adjustment improper. Check Tab Voltage and Backing Voltage adjustments. (Page 24) 3. Tabs not threaded correctly (missing the Tab Web Sensor). 34

39 TROUBLESHOOTING Stamp Placement Problems CONDITION Stamps are not placed in the same place on the media. When applied Stamp is not aligned on media. SOLUTION Stamp placement should be within +/- 1/8" 1. Check Pitch setting for the stamp. It should be "-0.010" more than the stamp size plus the space between the stamps. 2. Check the amount of transport pressure. Too little can cause the media to slip when it is being fed. 3. Check that pointer on the Tab Applicator Head is in the center of the stamp. 4. Check that Pressure Rollers (Unwind Roller and Tab Drive Roller are engaged. 5. Verify that Backing Type "Opaque" was selected. 6. Check/adjust the V-Tab settings. 1. The media may not be traveling along the Fixed Side Guide. Adjust the angle of the Guide Rollers by turning the knob on the Skew Guide. 2. Check the pressure between the Head and the Transport. Too much pressure will cause the media to flex as it is transported. Two or three stamps applied evenly spaced. Programming issue. When programming multiple stamps Separate was selected instead of Together. Or use the Auto Pos. feature. Reprogram the job. More than three stamps applied one after another on media when 1, 2 or 3 stamps are selected. 1. Improper Tab (Stamp) Sensor Adjustment. Check Tab Voltage and Backing Voltage adjustments. (Page 24) 2. Tabs not threaded correctly (missing the Tab Web Sensor). 35

40 TROUBLESHOOTING Tabber Operation Problems CONDITION Media feeds, but no tab or stamp is applied. Tabber Display powers ON, but Transport Power Button won't turn ON when pressed. Unwind Drive Rollers not advancing Tabs/Stamps into Bin. Tab web breaking at the Unwind Driver Roller. Tab Web breaks at or near the Tab Applicator Head peel point. Tabber Stops while tabbing. SOLUTION 1. Make sure media is feeding against the Fixed Side Guide. 2. Check Media Sensor for proper operation. 3. Check that tabs are present. Out of tabs? 4. Check that tabs are threaded correctly. 1. Check that the Emergency Stop switch is released. 2. Check that the Exit Roller Assembly is closed and locked. 3. Check that Jumper Plug is installed in the Safety Stop connection (located on side wall of Tabber.) 1. Check that the Power connection between the Reel Assembly and Tabber is securely connected. 2. Check that Unwind Rollers are engaged. 3. Check/clean Bin Sensor. 1. Tab Web wrapping around Rollers. Clean Unwind Roller. 2. Tabs not spinning freely on Reel. Reel improperly installed. 3. Check that Power connection between Reel Assembly and Tabber is securely connected. 1. Tabs not manufactured correctly. Tab backing cut when tabs were made; as Tab's peel backing is torn. Tab Web too weak. 2. Unwind Drive Rollers not advancing Tab stock. 3. Check that power connection between Reel Assembly and Tabber is securely connected. 1. Speed of tabbing exceeds maximum speed for the number of tabs being applied. Slow down Tabber. 2. Feeder speed is too fast, leaving too little gap between pieces. Slow down Feeder. 36

41 TROUBLESHOOTING Diagnostics A diagnostic function is built into the Tabber's software. Diagnostics are accessed through the Advanced key. Pressing the Diagnostic key will start the tests in order. To bypass a test press the Next key, to return to a test press the EXIT key. Tests in order are: 1. Voltage Test Displays the voltages in the power supply and logic. When you click Test ON, V-1 should be 12.0 volts for the main power supply. V-2, V-3 and V-4 are voltages on the logic board. Click EXIT to return to the Voltage Test screen or Next to go to the next test. 2. Encoder Test Tests if the Encoder is working. When you press Test ON, a number will display in Reading: Rotate the Exit Roller, if the number changes, the Encoder is working. Press Next to proceed to the next test. 37

42 TROUBLESHOOTING IMPORTANT REMOVE TABS FROM THE HEAD FOR THE REMAINING TESTS. 3. Clutch/Brake Test Tests the function of the Clutch and Brake for the head. The Test OFF position has the Clutch and the Motor OFF. Clicking Test ON will cause the Clutch and Motor to turn ON and the Brake to go OFF. You should be able to hear this action. Use the Next key to go to the next test. 4. Tab Supply Test Tests the function of Tab Web Sensor. In Test OFF: the Drive is OFF (Motor not running) and the Brake is ON (Tab Brake is locked). Clicking Test ON turns the Drive ON (Motor running) and turns the Brake OFF (Tab Brake unlocked). Use the Next key to go to the next test. 38

43 TROUBLESHOOTING 5. Tab Sensor Test Tests that the Sensor in the Tab Head is working. This test should be conducted with the tabs removed from the Tabber. Insert a piece of paper into the Sensor, the display should change from UNCOVERED to COVERED. Press Next to proceed to the Media Sensor Test. 6. Media Sensor Test Tests that the Media Sensor is working properly. Insert a piece of paper between the Sensor and the reflective lens. The display should change from UNCOVERED to COVERED. Press Next to proceed to the Keyboard Test. 7. Keyboard Tests keyboard function. Each time you press a key the display should show the name of the key in the Key Pressed line. Press EXIT last to return to the Advanced screen and exit the tests. This concludes the diagnostic testing. Any returns that do not match the above indicate a problem with the component tested. 39

44 APPENDIX Appendix - Specifications Speed Single Tab: Double Tab: Triple Tab: Material size Minimum: Maximum: Up to 20,000 pieces per hour Up to 12,000 pieces per hour Up to 8,000 pieces per hour (11" min. piece length) 3" x 5" 13" x 17" Material Thickness: Up to 3/8" Tab Size Roll Size: Minimum: Maximum: 3/4" x 3/4" 1-1/2" x 1-1/2" Number of Tabs: 1, 2, or 3 Tab Accuracy: +/- 1/16" Production Counters and Displays: Error Reporting: Features: Safety: Dimensions: Weight: Electrical: Up to 16" 3" core Life and Job Count and Production rate and speed YES Built-in Feeder (removable for in-line operation) Can apply multiple stamps Interlocks on all adjustments 25" W x 27" H (with reel) x 41" L (with feeder) 90 lbs. (approximately) 115VAC 50/60Hz Specifications are subject to change without notice. 40

45 INDEX Index A Advanced Features 17 Backlight, Control Panel 17 Diagnostic 18 Version 18 Appendix, Specifications 40 Assembly 5 B Backlight, Adjust Intensity 17 C Cleaning 30 Rollers and Belts 30 Sensors 30 Control Cable, Tabber/Feeder 2, 3 Control Panel 1 Clear Key 4 Display 4 Info Key 4 Keypad 4 Rub Key 4 Save Key 4 Soft Keys 4 Stop Key 4 D Diagnostics 37 Clutch/Brake Test 38 Encoder Test 37 Keyboard 39 Media Sensor Test 39 Tab Sensor Test 39 Tab Supply Test 38 Voltage Test 37 E Emergency Stop Input 2 Output 2 Tabber 4 Exceeding Tabbing Rate 14 F Feeder, Interface Cable 1 FF-30 Feeder 1 Adjusting 9 Installing 6 Fuse Feeder 3 Main 2 J Jams 33 Job# Key 18 Automatic 18 BACK 18 Manual 18 V-Tab 18 K Keypad, Control Panel 4 L Loading Tabs/Stamps 8 Lubrication 32 M Maintenance 30 Cleaning 30 Lubrication 32 Media Sensor Test 31 Tab Web Sensor Test 31 Media Guides 1 Media Height Adjustment Knob 1 Media Support 1 Media Thickness Adjustment, Feeder 3 Mode Switch, Feeder 3 O Offset Value 24 P Pitch, Tab 26, 29 Power Connection Feeder 3 Main 2 Power Switch Feeder 3 Main 2 Transport 4 Pressure Roller Assembly 1 Product Length Manual Input 29 Programming Tabber 17 R Reel 1 Reel Assembly, Installing 5 Reel, Take-up 1 S Specifications, Tabber 40 Speed Control Feeder 3 Tabber 4 T Tab Fold Positioning 11 41

46 INDEX Tab Sensor Automatic Adjustment 19 Manual Adjustment 21 Tab/Stamp Automatic Positioning 27 Clearing 31 Loading 8 Manual Positioning 23 Tabber Adjusting 10 Advanced 14 Job# 13 Mode 13 Operating 8 Pass-Thru Operate 13 Pre-programmed Job 15 Programming 17 Start-Up 13 Take-up Reel 1 Troubleshooting 33 Jams 33 Stamp Placement Problems 35 Tab Placement Problems 33 Tabber Operation 36 V V-Tab Automatic Adjustment 19 Manual Adjustment 21 42

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48 Copyright 2015 All rights reserved 02/23/2015 Part Number: 100-ATS-8900 Rev. E